Generac Power Systems 1277-0 Owner's Manual

Mobile Backup Power System Owner’s Manual

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Obey all safety messages that follow this symbol to avoid possible injury or death.

Model No. 1277-0 (7,200 Watt Mobile Backup Power System) Manual No. B4678 Revision 2 (06/20/2001)

Visit our Generac website: www.generac-portables.com

Problems?

Questions?

Before taking your unit

back to the store,

call the generator

helpline at

1–800–270–1408

M–F 8–5 CT

7200WATT

Generac Portable Products 7200 Watt Mobile Backup Power System

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EQUIPMENT

DESCRIPTION

This generator is an engine–driven, revolving field,
alternating current (AC) generator. It was designed to
supply electrical power for operating compatible electrical
lighting, appliances, tools and motor loads.This manual
contains information for a generator that operates
120 and/or 240 Volt, single phase, 60 Hz devices that
require up to 7,200 watts (7.2 kW) of power that pull up
to 60.0 Amps at 120 Volts or 30.0 Amps at 240 Volts.

CAUTION! Do Not exceed the generator’s

wattage/amperage capacity.Add up the rated watts of all
devices you are connecting to generator receptacles at one
time.This total should not be greater than 7,200 watts. See
“Don’t Overload the Generator” on page 11.

The generator’s revolving field is driven at about 3,600 rpm
by a single-cylinder engine.

Every effort has been made to ensure that information in
this manual is accurate and current.However, Generac
reserves the right to change, alter or otherwise improve the
product and this document at any time without prior
notice.

CAUTION! Do Not tamper with engine

governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipment.The generator supplies
correct rated frequency and voltage only when
running at proper governed speed.Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load.When adequate
engine power is not available engine life may be
shortened.

The Emission Control System for this generator is
warranted for standards set by the Environmental
Protection Agency. For warranty information refer to the
engine owner’s manual.

SAFETY RULES

This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit or
use it for any application it was not designed for. If you have
any questions about your generator’s application, ask your
dealer or consult the factory.

The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all–inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.

Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.

DANGER! You must isolate the generator from

the electric utility using approved transfer
equipment if this unit is used for backup power.

Failure to isolate the generator from the
power utility may result in injury or death to
electric utility workers and damage to the
generator due to a backfeed of electrical energy.

Whenever unit is providing backup power, the
electric utility must be notified.

DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate

this equipment outdoors where adequate ventilation
is available.

The engine exhaust from this product contains

chemicals known to the State of California

to cause cancer, birth defects,

or other reproductive harm.

WARNING:

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• The generator produces a very powerful voltage that can

cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child or
any unqualified person to operate the generator.

• Never handle any kind of electrical cord or device while

standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.

• Use a ground fault circuit interrupter (GFCI) in any damp
or highly conductive area (such as metal decking or steel
work).

• Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.

• Gasoline is highly FLAMMABLE and its vapors are

EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine. Comply

with all laws regulating storage and handling of gasoline.

• Do Not overfill the fuel tank.Always allow room for fuel
expansion. If tank is overfilled, fuel can overflow

onto a hot engine and cause a FIRE or an
EXPLOSION.

• Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.

• Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.

• Do Not insert any object through cooling slots of the
engine.You could damage the unit or injure yourself.

• Never operate the generator:

in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.

GROUNDING THE

GENERATOR

The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator end (Figure 1).

Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut
and to an earth–driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Be careful to keep the grounding wire attached after
connecting the stranded copper wire. However, local codes
may vary widely. Consult with a local electrician for
grounding requirements in your area.

Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.

Figure 1 — Grounding Wing Nut

Grounding Wing Nut

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Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.

If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in an
engine failure.

REMOVE GENERATOR

FROM CARTON

• Set the carton on a rigid flat surface with “This Side Up”
arrows pointing upward.

• Carefully open the top flaps of the shipping carton.
Review “Cold Weather Operation” on page 9.

• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged,call
the generator helpline at 1-800-270-1408.

• The Generator

• Power Transfer System (See Power Transfer System
manual for installation and operating instructions)

• Generator and Engine Owner’s Manuals

• 2 Bottles of Engine Oil

• Battery Float Charger

• Battery, Battery Tray,and Electric Start Components

• Wheel Kit

• Rechargeable Emergency Flashlight

INSTALL WHEEL KIT

To install your wheel kit, you need the following tool:

• Socket wrench with 1/2" or 13mm sockets.

• Philips head screwdriver.

Install Wheel Kit as follows: (See Figure 2)

• Place the generator on a hard flat surface.Temporarily
raise unit on blocks to ease assembly.

Figure 2 — Assemble Wheel Kit

Handle

Lanyard
Loop

Wheel

Axle

Spring Clip

Self Drilling Screw

Flat Washer

Retaining Pin

Wheel
Spacer

Locking

Nut

Flat

Washer

Flat

Washer

Handle

Release

Pin

Front wheel

Assembly

Cap Screw

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• Slide the axle through the holes in the brackets provided
on the generator cradle and then add the two spacers on
each protruding end of the axle.

• Slide a wheel on each end of the axle and secure with
washer and retaining pin.

NOTE: Install the wheels with the air inflation valve facing
outward.

• Slide the handle release pin lanyard loop onto the front
wheel assembly.

• Attach the front wheel assembly to the cradle with cap
screws, flat washers and lock nuts. Remove the
temporary blocks.

• Attach three spring clips to the generator using pre­threaded self drilling screws.

• Attach the handle onto the front wheel assembly with
fthe handle release pin or attach the handle to the side
of the generator using the spring clips.

• Check that all fasteners are tight and the tires are at the
proper inflation.The operating range should be 15-40 PSI.

INSTALLING TRAY AND

BATTERY

NOTE:The generator can be started manually.If you

choose not to use the electric start feature of this
generator, you do not need to install the battery.

For shipping purposes, the battery and battery tray were
not installed.The battery is fully charged for shipping.

Install the battery as follows:

• Find the battery tray and fasteners shipped loose in the
carton.

• Remove the four battery tray screws from cradle.

• Position the battery tray and install with supplied
hardware (Figure 3).

• Set battery onto tray with the positive terminal to the
right.

• Retain battery to tray with battery hold down bracket,
two J bolts, two lock washers, two flat washers and two
hex nuts (Figure 4).

• Connect the red battery cable from the engine starter
switch to positive (+) terminal on the battery
(Figure 5).

Figure 4 — Secure 12 Volt Battery

Figure 3 — Install Battery Tray

Figure 5 — Wire Connections

BLACK wire
from battery

RED wire
from battery

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• Connect the black battery cable to the negative (–)

terminal on the battery (Figure 5).

• Connect the other end of the black cable to the engine,

not the frame (Figure 5).

CAUTION! Be sure the BLACK cable is connected to

the engine mount and not the frame or damage to the
ground wire could occur.

BEFORE STARTING THE

ENGINE

Add Oil

CAUTION! Any attempt to crank or start the engine

before it has been properly filled with the recommended
oil may result in an engine failure.

To fill your engine with oil:

• Place generator on a level surface.

• Follow the oil grade recommendations and oil fill
instructions given in the engine owner’s manual.

NOTE:The generator’s revolving field rides on a
prelubricated and sealed ball bearing that requires no
additional lubrication for the life of the bearing.

Add Gasoline

WARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot. Do Not
light a cigarette or smoke when filling the fuel tank.

WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill.Allow about 1/2" of tank space for
fuel expansion (Figure 6).

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts, such as the
carburetor, fuel filter, fuel hose or tank during storage.Also,
experience indicates that alcohol–blended fuels (called
gasohol, ethanol or methanol) can attract moisture, which
leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.

To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.

Figure 6 — Typical Fuel Expansion Space

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KNOW YOUR GENERATOR

Read this owner’s manual and safety rules before operating your generator.

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.

120 Volt AC, 20 Amp
Receptacles

120/240 Volt AC, 30 Amp
Receptacle

Light

Air Cleaner

Spark Arrester
Muffler

Hour Meter

Fuel Tank

Light Switch

DC Float
Charger Jack

Circuit
Breakers

Run–Stop Switch

Choke Lever

Engine Start Switch

120 Volt AC, 20 Amp Receptacles — May be used to
supply electrical power for the operation of 120 Volt AC,
20 Amp, single phase, 60 Hz electrical lighting, appliance,
tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May
be used to supply electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.

Air Cleaner — Uses a dry type filter element and foam
precleaner to limit the amount of dirt and dust that gets in
the engine.

Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided

with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.

DC Float Charger Jack — Plug the battery float charger
into this jack and into a building wall outlet to provide a
trickle charge during storage.

Engine Start Switch - Press to start the engine.
Fuel Tank — Capacity of eight (8) U.S. gallons.
Grounding Wing Nut — (Not shown, see page 3) Used

for proper grounding of unit.
Hour Meter — The hour meter records the total number

of hours the generator has been running and is used to
schedule maintenance tasks.

Light, Light Switch — The light provides light during a
power outage so that the generator can be connected to
the Power Transfer System safely.The light is turned on and
off with the Light Switch.

Recoil Starter — (Not shown) Used as backup method
of starting the engine.

Run/Stop Switch — Set this switch to "RUN" before
starting. Set switch to "STOP" to turn off engine.

Spark Arrestor Muffler — Exhaust muffler lowers
engine noise and is equipped with a spark arrestor screen.

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OPERATING THE

GENERATOR

CAUTION! Never start or stop unit with

electrical loads connected AND with the connected
devices turned ON.

IMPORTANT:Always unplug the battery float charger
before starting the generator.

Starting the Engine

Disconnect all electrical loads from the generator. Use the
following start instruction steps by numerical order:

1. Turn the fuel valve to the “On” position (Figure 7).

3. Set the Run/Stop switch to “Run” position (Figure 8).

4. Place the choke lever in the “Full” choke position

(Figure 9).

5A. For electric starting, press start switch on generator

cradle.To prolong the life of the starter components,
press the starter button for no more than 15 seconds,
and pause for 30 seconds.

5B. For manual starting, grasp the recoil handle and pull

slowly until slight resistance is felt.Then pull rapidly
one time only to start engine.

• If engine starts, proceed to step 7.

• If engine fails to start, proceed to step 6.

6. Move the choke lever to “Half” choke position, and

pull recoil handle twice.

• If engine fails to start, repeat steps 4 thru 6.

7. Move choke lever to “Run” position. If engine falters,

move choke lever to “Half” choke position until the
engine runs smoothly and then to “Run” position.

NOTE: If engine still fails to start after 3 pulls, check for
proper oil level in crankcase.This unit is equipped with a
Low Oil Shutdown System. See engine manual.

Refer to the engine owner’s manual for complete
starting instructions.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after
starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.

• Do Not connect 240 Volt loads to the 120 Volt
receptacles.

Figure 9 — Choke Lever

“Full” choke
Position

Figure 7 — Fuel Shut-off Valve

Figure 8 — Run/Stop Switch

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• Do Not connect 3–phase loads to the generator.

• Do Not connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. When

not used with the Power Transfer System, add up the
rated watts (or amps) of all loads to be connected at one
time.This total should not be greater than the rated
wattage/amperage capacity of the generator. See “Don’t
Overload the Generator” on page 11.

Stopping the Engine

• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with electrical
devices plugged in and turned on.

• Let engine run at no–load for 30 seconds to stabilize the
internal temperatures of engine and generator.

• Move run/stop switch to “Stop”.

• Close the fuel shut–off valve.

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.

In an emergency, use the original shipping box as a
temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit.

• Start unit, then place box over it.
IMPORTANT: Remove shelter when temperature is

above 40°F [4°C].
For a more permanent shelter, build a structure that will

enclose three sides and the top of the generator:

• Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from that
shown in Figure 10.

• Ensure a minimum of two feet clearance between open
side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the
generator to prevent problems.

CAUTION!Neverrun unit indoors. Do Not

enclose generator any more than shown.

Figure 10 — Temporary Cold Weather Shelter

Wind

RECEPTACLES

120 Volt AC, 20 Amp, Duplex

Receptacle

Each receptacle (Figure 11) is protected against overload by
a 20 Amp push–to–reset circuit breaker.

Use each receptacle to operate 120 Volt AC, single–phase,
60 Hz electrical loads requiring up to 2400 watts (2.4 kW)
at 20 Amps of current. Use cord sets that are rated for
125 Volt AC loads at 20 Amps (or greater).

Light

A light is provided on the control panel to assist movement
in the dark.Turn on the light using the switch on the
control panel.

Always turn off the light when not needed as it drains the
generator battery.Turn off the light when the generator is
running.

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L14–30 plug with this receptacle. Connect a
4–wire cord set rated for 250 Volt AC loads at 30 Amps (or
greater) (Figure 12).You can use the same 4–wire cord if
you plan to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 3600 watts of power at
30 Amps for 120 Volts; 7200 watts of power (7.2 kW) at
30 Amps for 240 Volts.The outlet is protected by a 30 Amp
push–to–reset circuit breaker.

Use this plug to connect the unit to the Power Transfer
System (as described in the Power Transfer System owner’s
manual).

DC Float Charger Jack

Use battery charger jack with the provided battery charger
to keep the starting battery charged and ready for use.
Battery charging should be done in a dry location, such as
inside a garage.

• Plug charger into the unit’s “12V DC Battery Charger”
jack. Plug battery charger into a 120 Volt AC wall
receptacle.

• Unplug the charger completely when generator is being
started and while it is in operation.

• Use the charger whenever the generator is not in use to
prolong battery life.The charger has a built in float
equalizer and will not overcharge the battery, even when
plugged in for an extended period of time.

Hour Meter

The hour meter operates whenever the unit’s engine runs.
Use the hour meter to plan service tasks required in the
engine owner’s manual.

Generac Portable Products 7200 Watt Mobile Backup Power System

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Figure 12 — 120/240 Volt AC, 30 Amp, Locking Receptacle

Figure 11 — 120 Volt AC, 20 Amp, Duplex Receptacle

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DON’T OVERLOAD THE

GENERATOR

NOTE: Refer to this section when you are using the

generator without the Power Transfer System. Refer to
the Power Transfer System owner’s manual when operating
the generator in conjunction with the Power Transfer
System.Ask your Power Transfer System installer to review
load management techniques.

Overloading a generator in excess of its rated wattage
capacity can result in damage to the generator and/or
connected electrical devices. Observe the following, to
prevent overloading the unit:

• Add up the total wattage of all electrical devices to be
connected at one time.This total should NOT be greater
than the generator’s wattage capacity.

• If the appliance, tool or motor does not give wattage,
multiply 120 Volts times ampere rating to determine
watts (volts x amps = watts).

• The rated wattage of lights can be taken from wattage
listed on the light bulbs.The rated wattage of tools,
appliances and motors can usually be found on a data
plate or decal affixed to the device. Use Figure 13 below
as a general reference.

• Some electric motors, such as induction types, require
about three times more watts of power for starting than
for running.This surge of power lasts for only a few
seconds when starting such motors. Be sure you allow
for this high starting wattage when selecting electrical
devices to connect to your generator. First figure the
watts needed to start the largest motor.Add to that
figure the running watts of all other connected loads.

Recreational/Home Uses

Tool/Appliance....................................................Watts

AM/FM clock radio ....................................................................50

Light bulb....................................................................................100

Fan................................................................................................200

20" color TV ..............................................................................400

*Deep freezer ...........................................................................500

Personal computer and 15" monitor...................................800

*1/3 hp furnace fan blower....................................................800

Microwave oven........................................................................800

*18 cu ft refrigerator...............................................................800

Sump pump..............................................................................1000

Electric skillet..........................................................................1250

*½ hp water well pump.......................................................1400

*12,000 Btu window air conditioner ................................1400

Space heater............................................................................1800

Electric water heater ............................................................4000

Professional/Contractor Uses

Tool/Appliance....................................................Watts

*1/3 hp airless sprayer............................................................600

3/8" hammer drill .....................................................................600

Variable speed Sawzall® .........................................................960

½" power drill........................................................................1000

Quartz-halogen work light ..................................................1000

Belt sander...............................................................................1200

7 ¼" circular saw...................................................................1500

7 ¼" worm drive saw ...........................................................1600

*1½ hp air compressor........................................................1800

*10" power miter saw...........................................................1800

6" bench grinder.....................................................................1800

*6" table planer.......................................................................1800

*10" table/radial arm saw.....................................................2000

Wire feed welder...................................................................2400

* allow 3 times listed watts for starting this device

Figure 13 — Wattage Reference Guide

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SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . . . . . .9,000 watts

Continuous Wattage Capacity . . . . . . . . . . .7,200 watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0

Rated Maximum Continuous AC Load Current:

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .60.0 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .30.0 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . 8 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . .300 lbs.

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. Never operate a

damaged or defective generator.

Engine Maintenance

See engine owner’s manual for instructions.

CAUTION! Avoid prolonged or repeated skin

contact with used motor oil. Used motor oil has
been shown to cause skin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soap and water.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.

Generator Maintenance

Generator maintenance consists of keeping the unit clean
and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with snow,
leaves or any other foreign material.

NOTE: Do Not use a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voids and cracks of
the rotor and stator winding insulation.Water and dirt
buildup on the generator internal windings will eventually
decrease the insulation resistance of these windings.

Power Transfer System Maintenance

Refer to the Power Transfer System owner’s manual for
maintenance instructions.

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• A soft bristle brush may be used to loosen caked on dirt
or oil.

• A vacuum cleaner may be used to pick up loose dirt and
debris.

• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and opening on
generator.These openings must be kept clean and
unobstructed.

STORAGE

The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than 30 days,
use the following guidelines to prepare it for storage.

Generator Storage

• Clean the generator as outlined in “To Clean the
Generator.”

• Check that cooling air slots and openings on generator
are open and unobstructed.

CAUTION! Storage covers can be flammable. Do

Not place a storage cover over a hot generator. Let

the unit cool for a sufficient time before placing the
cover on the unit.

• Plug the battery charger into the DC float charger jack
on the control panel and into a building outlet.

Engine Storage

See engine owner’s manual for instructions.

Other Storage Tips

• Do Not store gasoline from one season to another.

• Replace gasoline can if it starts to rust. Rust and/or dirt
in gasoline can cause problems when that fuel is used
with this unit.

• Store in clean and dry area.

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TROUBLESHOOTING

Problem Cause Solution

Engine is running, but no
AC output is available.

1. Circuit breaker is open.

2. Poor connection or defective cord
set.

3. Connected device is bad.

4. Fault in generator.

1. Reset circuit breaker.

2. Check and repair.

3. Connect another device that is in
good condition.

4. Contact Generac service facility.

Engine runs good but bogs
down when loads are
connected.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. See “Don’t Overload the Generator”
on page 11.

3. Contact Generac service facility.

4. Contact Generac service facility.

Engine will not start; or
starts and runs rough.

1. Run/Stop switch set to Stop.

2. Dirty air cleaner.

3. Out of gasoline.

4. Stale gasoline.

5. Spark plug wire not connected to
spark plug.

6. Bad spark plug.

7. Water in gasoline.

8. Overchoking.

9. Low oil level.

10. Excessively rich fuel mixture.

11. Intake valve stuck open or closed.

12. Engine has lost compression.

1. Set switch to Run.

2. Clean or replace air cleaner.

3. Fill fuel tank.

4. Drain gas tank and fill with fresh fuel.

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain gas tank; fill with fresh fuel.

8. Put choke lever at “No Choke”
position.

9. Fill crankcase to proper level.

10. Contact Generac service facility.

11. Contact Generac service facility.

12. Contact Generac service facility.

Engine shuts down during
operation.

1. Out of gasoline.

2. Low oil level.

3. Fault in engine.

1. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Generac service facility.

Engine lacks power. 1. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

1. See “Don’t Overload the Generator”
on page 11.

2. Replace air filter.

3. Contact Generac service facility.

Engine “hunts” or falters. 1. Choke is opened too soon.

2. Carburetor is running too rich or
too lean.

1. Move choke to halfway position till
engine runs smoothly.

2. Contact Generac service facility.

Generac Portable Products 7200 Watt Mobile Backup Power System

14

SCHEMATIC

Generac Portable Products 7200 Watt Mobile Backup Power System

15

WIRING DIAGRAM

Generac Portable Products 7200 Watt Mobile Backup Power System

16

EXPLODED VIEW – MAIN UNIT

Generac Portable Products 7200 Watt Mobile Backup Power System

17

Item Part # Qty Description

1 HB4545 1 CRADLE
2 H92531 1 SUPPORT, Engine
3 H92731 1 SUPPORT, Engine & Muffler
4 92247 1 HOUSING, Engine Adapter
5 B1342G 1 ASSEMBLY, Rotor (Inclds Item 7)
6 B1897G 1 ASSEMBLY, Stator
7 65791 1 BEARING
8 96796 1 WASHER, Grommet Retainer

9 22129 2 LOCKWASHER, M8
10 86307 4 HHMS, 5/16-24 x 3/4 SEMS
11 47481 1 HHCS, 5/16-24 x 10.625
12 92609 2 MOUNT,Vibration
13 82857 4 MOUNT,Vibration
14 40976 2 SCREW, M8 - 1.25 x 20
15 66476 2 CAPSCREW, M6 - 1.0 x 12mm
16 92532 1 BRACKET, Muffler
17 22142 2 SCREW, 5/16 - 18 x 3/4
18 91153 1 MUFFLER
19 90239 1 GASKET, Muffler
20 81917 1 PIN, Roll 4mm x 10
21 78289 1 BRACKET, Starter Switch
22 22127 2 NUT, 1/4 - 20 Hex
23 22097 2 LOCKWASHER, M6
24 22287 2 SCREW, 1/4 - 20 x 3/4
25 66825C 1 CARRIER, Rear Bearing
26 74908 4 TAPTITE, M5-0.8 x 10
27 66449L 4 BOLT,Stator M6-1 x 165mm
28 65795 1 RECTIFIER, Battery Charge
29 66849A 1 TAPTITE, M5-0.8 x 20
30 67022 1 GROMMET, Rubber
31 84132 1 ASSEMBLY, Power Regulator
32 66386 1 ASSEMBLY, Brush Holder
33 66849 2 TAPTITE, M5-0.8 x 16
34 B4871 1 COVER, Bearing Carrier
35 22769 1 WASHER, Shakeproof Int. #10
36 86494 1 SCREW, M6-1.0 x 16 Wing
37 86292 1 HHCS, - #10 Self Driller
38 77395 4 NUT, Flange Lock - M6
39 83465 4 GROMMET,Tank
40 78831B 4 HHMS, M6-1.0 x 60, SEMS
41 80270 1 VALVE,Tank
42 78299 1 BUSHING, Plastic Tank
43 B4363 1 CAP, Fuel Gauge

Item Part # Qty Description

44 B1998 1 TANK, Fuel Assy.

(Includes Items 41 & 42)
45 BB4675 1 SHIELD, Heat
46 92665 1 INSULATION, #2-1/4" Thick
47 85000 1 CLIP, Insulation
48 14353621 1 WIRE, Ground
49 26850 2 LW, EXT, Shakeproof M6
51 92982 1 DECAL, Danger
52 B2153 7 SELF DRILLER,12 - 14 x 7/8"
53 189160 12 NUT, 5/16 - 18 Serrated Flange
54 B5051 2 DECAL, Heat Shield
57 B4553 1 DECAL, Control Panel
58 B4690 1 ASSEMBLY, Control Panel
59 NSP 1 ENGINE
60 22531 2 HHCS, 5/16-18 x 1-3/4"
62 93826 1 DECAL, Start Instructions
63 BB4674 1 SHIELD, Heat
64 56893 5 CRIMPTITE, 10-24 x 1/2
65 77282 1 SWITCH, Starter
66 B4986 1 DECAL, Ground
68 45771 2 NUT, M8 Hex
69 H96925 1 BRACKET, Battery Tie-Down
70 96924 2 J-BOLT,M8
71 58443 4 CRIMPTITE, 1/4 - 20 x 5/8
72 HB4672 1 TRAY, Battery
73 11353621 1 BATTERY CABLE, Negative
74 52618 2 HHCS, M5 - 0.8 x 12
75 19953621 1 BATTERY CABLE, Postive
76 52856 2 NUT, M5 Hex,Flange
77 23897 2 WASHER, M5 Flat
78 22145 2 WASHER, M8 Flat
79 B4489 1 BATTERY

Items Not Illustrated:

72347 1 PLUG, Spark
73111 1 ELEMENT,Air Cleaner
B4177 1 CHARGER,Battery 12V
B4678 1 MANUAL, Generator Owner’s
A8927 1 MANUAL, Engine Owner’s
84882 1 WRENCH, Spark Plug
BB3061 2 OIL, 28 oz.
NSP 1 FLASHLIGHT

PARTS LIST – MAIN UNIT

Generac Portable Products 7200 Watt Mobile Backup Power System

18

EXPLODED VIEW AND PARTS LIST – WHEEL KIT

Item Part # Qty Description

1 89742 2 ASSEMBLY,Wheel 4 x 12 Dia.
2 B4905 1 ASSEMBLY,Wheel 4 x 12 Hub

Ext.
3 93693 1 AXLE, 5/8" Zinc Plate 679
4 93693E 1 AXLE, 5/8" Zinc Plate 150
5 HB4122 1 ASSEMBLY, Handle Hitch
6 HB3375 1 WELDMENT, Fork Pivot
7 HB4115 1 ASSEMBLY, Pivot
8 B4134 1 GRIP, Handle
9 B4135 1 PIN,Handle Release

Item Part # Qty Description

10 89635 2 SPACER,Wheel
11 22247 4 WASHER, 5/8" Flat
12 87005 4 PIN, Quick Release 1/4"
13 96796 4 WASHER, Grommet Retainer
14 52858 2 NUT, Locking M8 - 1.25
15 52203 2 HHCS, M8 - 1.25 x 70
16 46476 2 CAP PLUG, 1 Sq. x 16 Ga Tube
17 B2427B 3 CLIP, Spring
18 B5164 3 SELF DRILLER,#10 - 16 x 3/4"
19 186569 3 BUMPER, Recess

Generac Portable Products 7200 Watt Mobile Backup Power System

19

EXPLODED VIEW AND PARTS LIST – CONTROL PANEL

Item Part # Qty Description

1 BB4689 1 PANEL, Control
2 23897 4 FLAT WASHER, M5
3 49226 4 LOCK WASHER, M5
4 91526 4 PPHMS, M5 - 0.8 x 12
5 B4695 1 LIGHT, 12V Backup
6 B4694 1 JACK, Coaxial DC Power
7 20984 1 SWITCH, Rocker (On - Off)
8 77604 1 METER, Hobbs Hour
9 43182 2 LOCK WASHER, M3

10 51714 2 NUT, M3 - 0.5 Hex
11 75207 2 CIRCUIT BREAKER, 20A Manual

Reset

12 82081 1 BREAKER, 30A Manual 2-Pole
13 23365 6 WASHER, #8 Shakeproof
14 43437 1 OUTLET, 120/240V - 30A
15 43180 6 FLAT WASHER, M4
16 22264 6 LOCK WASHER, M4

Item Part # Qty Description

17 51715 6 NUT, M4 - 0.7 Hex
18 68759 2 OUTLET, 120V - 20A Duplex
19 28739A 2 WRAP, 4" Black Tie
20 84135 1 GROMMET, Rubber
21 84409 1 SLEEVING, Flexo HW 1/2 x 7"
22 B1127 1 GROMMET, Rubber
23 84335 1 ASSEMBLY,Wire Harness
24 64526 8 SCREW, #6-32 x 3/8" Self

Tapping
25 83970 1 BOARD, System Control
26 64525 4 STAND OFF, 3/4" Hex
27 B92069 1 BOX, Control Panel
28 36900 4 PPHMS, #6-32 X 1/4"
29 23364 4 WASHER, #6 Shakeproof
30 B4900 1 ASSEMBLY,Wire Harness
31 74138 1 ADAPTER, Male Disconnect
32 B5112 1 ASSEMBLY, Diode

PORTABLE GENERATOR LIMITED WARRANTY

GENERAC PORTABLE PRODUCTS, LLC (hereafter referred to as the COMPANY) warrants to the original purchaser
that the components in its portable generator will be free from defects in materials or workmanship for the items and
period set forth below from the date of original purchase.This warranty does not include the gasoline engine when
furnished or attached because such engine is covered solely by the engine manufacturer’s warranty. Starting batteries are
not warranted by the COMPANY.The term “original purchaser” means the person for whom the generator is originally
purchased.This warranty is not transferable and applies only to portable generators driven by an overhead valve engine.

Warranty Schedule:

Consumer* Commercial*

Engine Warranted solely by the engine manufacturer
All other parts 2 years (2nd year parts only) 1 Year

With the exception of European Community Countries, all units bound for export shall be warranted for One (1)
Year in Consumer applications, and 90 days in Commercial applications as defined below.

*NOTE:For the purpose of this warranty "consumer use" means personal residential household use by
original purchaser.This warranty does not apply to units used for prime power in place of utility.
"Commercial Use" means all other uses, including rental, construction, commercial and income producing
purposes. Once a generator has experienced commercial use, it shall thereafter be considered a
commercial use generator for the purposes of this warranty.

During the warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**.All transportation costs under warranty, including
return to the factory if necessary, are to be borne by the purchaser and prepaid by the purchaser.This warranty does not
cover normal maintenance and service and does not apply to a generator set, alternator, or parts which have been
subjected to improper or unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding,
improper maintenance, repair or storage so as, in the COMPANY’s judgement, to adversely affect its performance and
reliability.

**NORMAL WEAR: As with all mechanical devices, the generator needs periodic parts service and
replacement to perform well.This warranty will not cover repair when normal wear has exhausted the life
of a part or generator.

THERE IS NO OTHER EXPRESS WARRANTY.THE COMPANY HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES,INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW.THE DURATION OF
ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS
SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL,INCIDENTAL OR SPECIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY
RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES,SUCH AS THE LOSS OF TIME OR
THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE
EQUIPMENT:AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN

WARRANTY.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you.This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.

For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Or look on the
internet at www.generac-portables.com.Warranty service can be performed only by a COMPANY authorized service
facility.This warranty will not apply to service at any other facility. At the time of requesting warranty service, evidence of
original purchase date must be presented.

GENERAC PORTABLE PRODUCTS, LLC

Jefferson,Wisconsin U.S.A.